Hi again,
We started out discussing IRS hub rebuilds here. I sort of sidetracked it into discussion of solid axle hub woes. So, let me try to get it back on the original topic...
Since I'm not all that familiar with the later cars, I pulled out Roger William's "Restoring TR5/250/6" last evening and looked up the section on IRS hubs. There are quite a few differences between the non-IRS and IRS hubs, and different issues with each.
One key thing is that the solid axle, if it breaks, will not lose the wheel completely. The IRS wheel will come off completely if an axle sheers. So, as disastrous a broken axle might be, it's even more of a safety concern with the IRS cars.
Williams strongly recommends doing a service exchange from a good TR vendor, rather than trying to rebuild IRS hubs yourself or having someone unfamiliar with TRs working on them. Some special and expensive tools are necessary. Plus there are some strongly recommended procedures, such as crack-detecting the outer axles before reusing them.
Other important things to check are the mounting studs in the trailing arm. Apparently these were originally tapped with fine thread, and really should be coarse in aluminum. So, they are prone to stripping. Beyond just rethreading and swapping to studs that are NC on the end threaded into the trailing arm, installing helicoils or time-serts might be a good precaution.
Alan Myers
San Jose, Calif.
'62 TR4 CT17602L